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Going Baroque wrote:
When cutting foam core (styrofoam), I find that a new blade in a box cutter works pretty well. The first cut is not very deep; it's just to create a groove for the next pass. If you are patient, and make multiple shallow passes, the mess really isn't that bad. I only do 2 or 3 passes, and the edges are clean enough that I can cover them immediately with gaffer tape without any sort of clean up. I cover the edges with a strip of gaffer tape, then I use another strip for the hinges. The first one...Show more →
The trick for cutting FomeCore is to use a sharp utility knife and cut it at a slight angle, maybe 70 degrees instead of a 90 degree straight up and down. This will make a clean cut the first time and you don't need bread knives or multiple passes. Be careful, the cut edge is verry sharp, you may want to use some tape along the edge, or rub it with a piece of wood or something to dull it.